doering selection of grinding media klein

8/9/2019 DOERING Selection of Grinding Media Klein

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The Selection of Grinding Media

One of the highest cost consumables in the

operation of a Mineral Processing plant is theGrinding Media, consumed in the various types

of mills utilised for feed or size reduction.

To most existing operations and consultants

planning the flow charts of new installations,

the media is seen as a necessary commodity

that can be met by either forged balls or cast

High Chrome products. Unaware of a proven

low cost alternative!

The manufacturing process of similar types of

grinding media is a major factor. The process

of forging balls is similar throughout the world,

certain costs have to be accepted regardless of

the country of origin, effecting the selling price

of the product.

In recent times, the existence of a quality low

cost alternative has allowed metallurgists to

make use of smaller media, without the higher

pricing automatically linked to the supply of

small balls typically used in regrind mills.

Why should we use smaller media for

secondary and regrind mills?

A high percentage of grinding action in a ball

mill relies upon friction, being the contact of

mill feed or with the grinding media surface.

To optimise mill performance, the grindingmedia surface area should be as large as

possible, with the media retaining sufficient

mass to accommodate the incoming feed

characteristics. Net result an increase in

throughput or a finer end product.

We obtain that increase in surface area by

using smaller grinding media!

The energy consumption will drop while the

throughput increases due to the smaller media.

The mass of the charge and therefore the

energy input stays constant.

By retaining a constant mass of the charge

and reducing the media size, we obtain higher

throughput [ t/h]! For the same energy input,

this translates to a reduction in specific energy

[ KWh/t ].

To make a significant impact upon media costs,

it is essential to find a lower cost method of

manufacture. Without that breakthrough, cost

of locally produced and imported balls will not

vary too much, with quality and support issues

determining the ultimate supplier.

DOERING International GmbH .. Wetzlarer Straße 10 .. 35764 Sinn, Germany .. Phone +49 (0) 2772 / 5001-0 .. Fax +49 (0) 2772 / 5001-46 .. [email protected] .. www.cylpebs.com


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The German company, DOERING International

GmbH, is the leading supplier of such an

alternative Grinding Media, in it’s range of

cylindrical media known as Cylpebs.

Manufactured in metal moulds, the process

aligns a „grown“ structure perpendicular to the

working face of the media, giving the product

amazing shape retention.

Operations currently using balls will be well

aware that superior shape retention is a major

advantage over the final 50% of media life,

greatly improving grinding capacity.

A unique feature of Cylpeb manufacturing

is the ability to supply a range of media at a

single price structure. DOERING Cylpebs within

the size range of 20 mm to 50 mm are

available at the same price! Without being

disadvantaged, metallurgists can make use

of the incremental sizes available to optimise

plant performance.

DOERING technical input controls the

manufacturing process in selected foundries

located in Germany and other countries

worldwide, the resulting high quality product

rating as a proven cost effective grinding tool.

A ball has the smallest surface area relative to

it’s weight! Cylpebs have a surface area

advantage over balls of equal weight of

14.5 %, a bulk density of 4.9 t/m 3 versus balls

of 4.5 t/m 3 . Therefore a typical mill charge can

obtain 25% more available grinding surface

area, resulting in greater throughput and

lower energy consumption.

You are invited to learn more about this

range of media, with a proven capacity to

reduce operating costs, by logging on to the

DOERING International website.

The site has been developed to assist

metallurgists to correctly size grinding media,

utilising the most cost efficient product

available on the market.

In addition to interesting technical data, the

site incorporates the world renowned “Bond

Formula“ in an interactive presentation. By

inserting your milling operating parameters

into the boxes provided, the optimum media

size as nominated by Bond will be given.




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Required data to make use of this feature is as

follows:

• F80 of the mill feed

• WI Bond work index of the feed (a listing of

common indexes is provided on our website)

• Percentage of critical mill speed

• Specific gravity of mill feed

• Inside mill diameter

• Wet or Dry grinding process

Changing the input data to the boxes will

enable technicians to check current media

utilised, the effects of differing feed size and

review possible alternatives.

For sites not having the necessary data to

utilise the interactive size calculation, we refer

you to the additional pages on our website,

for more details on critical mill speed and SG

of mill feed. We offer to calculate the F80 on

presentation of sieve analysis of your mills.

To start your cost reduction programme, call

up www.cylpebs.com and talk to us, we have a

truly unique product that should be

investigated for use on your site!

For communication, use the e-mails indicated

on the website www.cylpebs.com or contact us

by Telefax, DOERING International

headquarters: +49 (0) 2772 / 5001-46 .



doering selection of grinding media klein

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